KR101004931B1 - Bank amount automatic cotrol system - Google Patents

Abstract

PURPOSE: An automatic apparatus for controlling bank amount is provided to measure material condition using a camera. CONSTITUTION: An automatic apparatus for controlling bank amount comprises: a first and second light source(105,106) which is mounted at the upper portion or side portion of a space contacting with a first roll(101) and second roll(102); a first and second camera(107,108) for acquiring the image of bank portion(104); a main control unit(109) which transfers a main computer(110) by controlling display of corresponding bank amount; an input and output terminal unit(111); a position part(113) for transfers the signal to a submotor(116); and an alarm part.

Description

Bank amount automatic cotrol system

The present invention relates to a bank amount automatic control device, and more particularly, the situation of the material (rubber, etc.) supplied between the calendar roll (calendar roll) by measuring the situation with a camera to notify the operator immediately when a supply failure occurs A bank amount automatic control device for automatically controlling a constant and uniformly automatic bank amount.

As is well known, for example, the tire manufacturing process includes a mixing process of mixing various materials such as rubber, filler, vulcanizing agent and the like for use as an intermediate material.

In order to mix the various materials in this way, as shown in FIG. 1, a method of feeding and milling the material 13 to be mixed between the roll 11 and the roll 12 is employed.

In the milling operation as described above, the bank amount 14 of the material 13 stacked on the rolls 11 and 12 has a great influence on the properties of the material to be milled.

Therefore, the calender should be adjusted to the amount of banks formed by the material 13 between the gaps of the rolls 11 and 12.

That is, in the calender system, the bank amount has a large influence on the change of the rubber properties. This is also a major factor in the change in the short term of calendar products.

If the amount of the banks 14 to be milled is small, the mixtures pass through the rolls 11 and 12 in a state where they are not sufficiently mixed, and thus the mixing efficiency is lowered. In many cases, sheet formation is difficult when supply and discharge are continuously performed, such as calendering.

On the other hand, when the bank amount 14 is large, there is a possibility that the passage of the material between the rolls 11 and 12 may be delayed and scorched and hardened on the rolls 11 and 12. Sufficient cooling by the surface of the is not made.

In order to solve such a problem, a method of obtaining a silhouette of bank material has been conventionally employed to adjust the bank amount 14.

The former uses a video camera, a screen, and a light source to determine the bank amount by the area of the silhouette. The latter suggests a method in which the television camera converts and measures the bank roll shape into two signals, black and white. It has been.

However, in the former case, a method using a digital imaging technique, in which mist occurs due to the temperature of the material in the bank, such as a method of acquiring a material in the bank as a light color image against a dark color background or using a video camera. Alternatively, a mechanical device provided in advance is provided on the rubber supplied above the rolls 11 and 12, so that when the machine is operated and obstructs or obstructs an image, information of the correct bank amount on the rolls 11 and 12 is obtained. There was a problem that was difficult to do.

On the other hand, in the latter case, as a direct image method, there is a problem in that it is not possible to compensate the brilliance in a calender roll with a brilliance.

Therefore, the present invention has been proposed to solve the above problems of the prior art, the object of which is to measure the situation of the material (rubber, etc.) supplied between the calender rolls with a camera to the worker when the abnormality of material supply occurs It is to provide an automatic bank amount control device that promptly informs and automatically controls a constant and uniform amount of material bank.

In order to achieve the above object, the present invention is the first and second roll is installed on the upper side or side of the space adjacent to the first, second to brighten the bank portion generated between the first and second roll The first and second cameras for acquiring an image of the bank portion by the two light sources, the brightness of the first and second light sources, and the first and second cameras while controlling the operation of the first and second cameras. The main control unit removes the noise of the image acquired through the camera, processes the image, measures the bank amount to make a database, displays the corresponding bank amount, and transfers it to the main computer, and input and output signals of the main computer. Input and output terminal parts for automatic position control, automatic speed control and alarm, automatic position control for transmitting signals to the sub-motor for automatic control of the position of the conveyor, and automatic control of the speed of the conveyor. Including the automatic speed control and alarm unit for sending an alarm signal indicating that the information when an error occurs in the input and output materials supply is connected to the terminal section is characterized in that configured.

The main controller may include a camera controller for controlling operations of the first and second cameras, a noise of an image acquired through the first and second cameras, and a bank edge by searching for a bank edge. An image processor for processing an image using a convolutional image processing technique, a bank amount measurement and database unit for measuring and databaseting an average bank amount processed by the image processor, and a bank dress in the image processor After the hold pattern value is obtained, the display unit may display the information processed in real time through data validation and data reliability check.

The invention is also characterized in that the second camera and the second light source are configured to measure between another calendar roll.

The image processor may be configured to transmit an alarm signal for bank error correction when a bank error occurs.

In addition, the bank error correction is characterized in that the error is eliminated by smoothing the bank position in the thresholded profile.

In the present invention, the measurement of the bank amount is determined by selecting one of the V pattern or the L pattern according to the working range by setting the measurement range limit line, the upper limit and the lower limit, and the threshold size, the threshold level, It is characterized in that the bank amount is divided and searched by adjusting the threshold calculation and the DffBand values.

According to the automatic bank amount control apparatus according to the present invention, the situation of the material (rubber, etc.) supplied between the calender rolls is measured with a camera to immediately notify the operator when an abnormality in the material supply occurs, and also provides a stable and minimal By automatically controlling the bank amount, it is possible to reduce the short term change of the calendar product by more than 50%, thereby improving the quality of the calendar product.

 [Example]

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

2 is a block diagram of the entire automatic bank amount control apparatus according to the present invention, and FIG. 3 is a detailed block diagram of the main control unit of the automatic automatic bank amount control apparatus according to the present invention.

As shown in FIG. 2, the present invention is provided between the first roll 101 and the second roll 102 by being installed on the upper side or the side of the space adjacent to the first roll 101 and the second roll 102. The first and second light sources 105 and 106 to brighten the bank portion 104 to be brightened, and the first to obtain an image of the bank portion 104 by the brightness emitted from the first and second light sources 105 and 106. Control the operations of the second cameras 107 and 108 and the first and second cameras 107 and 108 while removing noise and processing images of the images acquired through the first and second cameras 107 and 108 The main controller 109 transmits the measured amount to a database (DB) and displays the corresponding bank amount to the main computer 110, and automatically inputs and outputs the input and output signals of the main computer 110. ), The sub-motor 116 to automatically control the position of the input / output terminal 111 and the conveyor C, which are transmitted to the automatic speed control unit 114 and the alarm unit 115. It is connected to the automatic position control unit 113 for transmitting a signal to the automatic speed control unit 114 for automatically controlling the speed of the conveyor (C), and the input and output terminal unit 111, and when a material supply error occurs, It consists of an alarm unit 115 for transmitting an alarm signal informing the matter.

In addition, as shown in FIG. 3, the main controller 109 controls the operation of the first and second cameras 107 and 108 through the camera controller 109a and the first and second cameras 107 and 108. An image processor 109b which removes noise of the acquired image, retrieves a bank edge to obtain bank threshold values, and processes the image by a convolution image processing technique; and through the image processor 109b. The bank amount measurement and database unit 109c for measuring and converting the converted bank amounts into a database, and the bank threshold pattern values are obtained by the image processing unit 109b, and then the corresponding information processed through data validation and reliability verification are processed. It consists of the display part 109d which displays in real time.

In addition, the image processor 109b is configured to transmit an alarm signal for bank error correction when a bank error occurs.

The operation of the automatic bank amount control apparatus according to the present invention configured as described above will be described in detail with reference to FIGS. 4 to 14.

First, as shown in FIGS. 2 and 3, the first and second light sources 105 and 106 are disposed above the space where the first roll 101 and the second roll 102 are adjacent to each other, so that the first roll 101 is provided. And the bank portion 104 generated between the second roll 102 is brightened.

The first and second cameras 107 and 108 capture and acquire an image of the bank part 104 brightly illuminated by the first and second light sources 105 and 106.

The main controller 109 controls the operation of the first and second cameras 107 and 108, removes noise of the image acquired through the first and second cameras 107 and 108, processes the image, measures the bank amount, and stores the database. (DB) to control the display of the bank amount and transfer to the main computer (110).

The main computer 110 transmits the input and output signals to the automatic position control unit 113, the automatic speed control unit 114, and the alarm unit 115 through the input and output terminal 111, and in the form of TCP-IP communication. It is sent to the Factory LAN.

The automatic position controller 113 receives the input and output signals from the main computer 110 via the input and output terminal 111 and sends a signal to the sub-motor 116 to automatically adjust and control the position of the conveyor C. To pass.

The automatic speed controller 114 automatically controls the speed of the conveyor C by receiving input and output signals from the main computer 110 via the input and output terminal 111 to maintain the average bank amount.

The alarm unit 115 receives the input and output signals through the input and output terminal 111 from the main computer 110 and transmits an alarm signal so that an operator immediately knows the corresponding matters when an abnormality in material supply occurs.

As shown in FIG. 3, the main controller 109 includes a camera controller 109a, an image processor 109b, a bank amount measurement and database unit 109c, and a display unit 109d. 109a controls the operations of the first and second cameras 107 and 108,

The image processor 109b removes noise mixed in the images acquired through the first and second cameras 107 and 108, and determines how wide an area is to be examined when looking for a bank.

In addition, the image processor 109b determines the inclination of the change of the image, adjusts the position of the bank, and smoothes the position of the adjusted bank so that the bank edge appears.

In addition, the image processor 109b transmits an alarm signal for bank error correction when a bank error occurs.

The bank amount measurement and database unit 109c measures and converts the bank amount processed by the image processing unit 109b into a database.

After the display unit 109d obtains the bank threshold pattern value from the image processor 109b, the display unit 109d displays the corresponding information processed through data validation and reliability verification in real time.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

4A to 4C are diagrams illustrating a noise removing process of an image acquired by a camera.

As shown in FIG. 4A, the images acquired by the first and second cameras 107 and 108 include random noise components. Therefore, the noise components are processed through a mathematical image processing process as shown in FIG. 4B. Remove

Next, as shown in Fig. 4C, the distorted data is corrected by frequency adjustment and processed into more significant data.

Then, the convolution image processing technique is performed to convert the data into the simplest data while maintaining the components of the original image.

5A and 5B are diagrams showing an example of different mask sizes.

The mask size is used to remove random noise of the cameras 107 and 108 and makes the image smooth.

This affects only the internal process, which is related to the accuracy of the bank amount calculation.

By displaying the externally visible image as an unprocessed image, no change of the visually visible image occurs.

6A and 6B are graphs showing an example for explaining the threshold pattern (ThreshHold Parrern).

This threshold pattern (ThreshHold Parrern) allows one to select between the V pattern and the L pattern.

Here, the V pattern is a method for finding a darker region than the surroundings. As shown in FIG.

On the other hand, the L pattern is a method of finding a point brighter than the surroundings, and the influence of the threshold size (ThreshHold Size), the threshold level (ThreshHold Level), and the threshold count (ThreshHold Count), which will be described later, is the same, but the left is the same as the V pattern. Instead of determining all of the right side, as shown in FIG. 6B, if there is a portion brighter than the threshold level (ThreshHold Level) in the advancing direction, the portion is determined as the bank position.

7A and 7B are graphs of one example for explaining the threshold size.

This threshold size is a measure of how wide the area is to be examined when looking for a bank.

 For example, when the value of the threshold size (ThreshHold Size) is small as shown in FIG. 7A, the operation is performed in a minute change. When the value is large as shown in FIG. 7B, the apparent change is determined as the bank position.

8A and 8B are graphs of one example for explaining the threshold level.

This threshold level (ThreshHold Level) determines how rapidly the slope of the change changes.

9A and 9B are graphs of one example for explaining a threshold hold count.

This threshold count (ThreshHold Count) adjusts the bank position, affects the calculation position, and is calculated small when the bank amount is small as shown in Fig. 9A, and when the bank amount is large as shown in Fig. 9A. It is calculated greatly.

The threshold size (ThreshHold Size), the threshold level (ThreshHold Level), and the threshold count (ThreshHold Count) are organically operated. If one value is changed, the threshold value must be converted to find an optimal value.

10A and 10B illustrate a process of searching for bank edges.

As shown in FIG. 10A, an algorithm for determining the position of a bank according to characteristics of an image must be different, and the accuracy of a threshold varies according to the quality of the image.

As shown in FIG. 10B, there are various methods for obtaining a threshold pattern value depending on the type of image to be analyzed.

In FIG. 10B, the V pattern represents the search of the darkest part, the L Pattern represents the search of a certain brightness or more, and the Hi Pattern represents the search of the brightest part.

11 is a diagram showing a relationship between image quality and threshold accuracy.

As shown in Fig. 11, the image quality and the threshold accuracy are proportional to each other.

In the present invention, the first and second light sources 105 and 106 are provided to highlight the characteristics of the image in order to obtain better image quality.

For example, if the brightness (lighting) performance of the light source is degraded, a very sophisticated software algorithm is required to compensate for this, which increases the difficulty of program development, thereby increasing the software development cost. All.

12 is a diagram illustrating a process of correcting a bank error.

After the bank threshold value is obtained as shown in FIG. 12, the data is displayed after the data validation and the data reliability are confirmed. If an error occurs, an alarm signal is sent (Alarm On).

Figure 13a shows the acquired image when the camera is installed on the top, Figure 13b shows the acquired image when the camera is installed on the side.

The acquired image varies depending on the installation positions of the first and second cameras 107 and 108, which affects the bank amount measurement.

That is, the calculation method of the bank amount calculation profile applied varies according to the installation positions of the first and second cameras 107 and 108.

Fig. 14A is a graph showing the bank amount calculation profile when the camera is installed on the upper part, and Fig. 14B is a graph showing the bank amount calculation profile when the camera is installed on the side.

Fig. 15 is a diagram showing upper and lower limit values for calculating the average bank amount when the camera is installed on the upper portion.

In Fig. 15, OL1 and OL2 are the measurement range limit lines, CL is the center line (profile reference line), H1 and H2 are the upper limits, and L1 and L2 are the lower limits.

Here, the images outside the lines OL1 and OL2 are removed.

When a bank amount exceeding the upper limit H1, H2 is generated, an alarm signal is sent and the material supply is cut off at the corresponding position.

When measuring the bank amount below the lower limit (L1, L2), an alarm signal is sent and control is made to supply material at the corresponding position.

If the camera is installed on the side, the lower limit lines L1 and L2 may be set to match the center line CL.

16 is a diagram illustrating an example of parameter setting application.

In the setting of the parameter, there is a search over a certain brightness (L Pattern) and the search for the darkest part (V Pattern). Such a parameter means a threshold pattern value (ThreshHold Parrern).

For example, if the threshold pattern value is "0", the darkest part is searched (V Pattern) to obtain a profile. If the threshold pattern value is "1", the search is performed for a predetermined brightness or more (L Pattern). The profile is obtained by obtaining the profile. If the threshold pattern value is "2", the brightest part is searched (Hi Pattern) to obtain the profile.

In this way, an accurate profile can be obtained by changing the threshold pattern value according to the result of obtaining the image.

That is, the setting of the camera should change the parameter according to the image.

This parameter causes a large difference in the profile representing the bank amount even in the same image depending on the brightness of the light sources 105 and 106.

CamGrabTime is set to milliseconds (mSec), and the minimum value is 1000/60 = 17.

Camera shooting is done at a quick time interval, but bank calculation can be adjusted to allow calculation at a slower period (BankCalcTime).

Namely, the setting is made in consideration of the CPU capacity of the main computer 109.

In FIG. 16, DffBand smoothes a bank position of a threshold position and removes an error. The smaller the value, the more smoothing occurs. Means that.

On the left side of Fig. 16, the parameter is changed so that the profile of the image excluding the shadow appears in the image, thereby representing the actual bank amount.

In the left profile of FIG. 16, the upper portion shows a profile of an image acquired by the other camera among the two cameras 107 and 108.

17 is a diagram showing another example of the parameter setting application.

In the left image of Fig. 17, for example, it is assumed that the appearance of the shadow portion is included in the actual bank amount, so that the set parameter is changed to adjust the profile of the image.

In the left profile of FIG. 17, the upper portion shows a profile of an image acquired by the other camera among two cameras 107 and 108.

That is, the lower profile is the profile matched with the image.

18 is a screen showing an example of profile storage and display, in which a sampling time is set for a continuously measured profile, and the measured date and time are stored in real time to analyze history as needed (Sigma, Max, Min). At the same time, it can be seen at a glance.

The profile save (BankProfileSave) is stored for each period described above (BankCalcTime).

19 is a graph illustrating a change in short term when a calendar is applied.

FIG. 19 shows a value measured for 3 minutes by stopping the total scanner at one point of the product in the Honeywell System.

That is, the value measured for 3 minutes is Max = 1235 gsm, Min = 1136 gsm, and the difference value 99 gsm represents a weight change of about 8%.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention.

Therefore, the technical scope of the present invention should not be limited to the contents described in the embodiments, but should be defined by the claims and their equivalents.

1 is a schematic structural perspective view of a conventional bank amount adjusting device.

2 is an overall block diagram of an automatic bank amount control apparatus according to the present invention.

Figure 3 is a detailed block diagram of the main control unit of the automatic bank amount control apparatus according to the present invention.

4A to 4C are diagrams illustrating a noise removing process of an image acquired by a camera.

5A and 5B are views of one example of different mask sizes of FIGS. 5A and 5B.

6A and 6B are graphs of an example for explaining the threshold pattern (ThreshHold Parrern).

7A and 7B are graphs of one example for explaining the threshold size.

8A and 8B are graphs of one example for explaining the threshold level.

9A and 9B are graphs of one example for explaining the ThresholdHold Count.

10A and 10B illustrate a process of searching for bank edges.

Fig. 11 is a diagram showing a relationship between image quality and threshold accuracy.

12 illustrates a process of correcting a bank error.

13A and 13B are views illustrating acquired images when the cameras are installed on the top and side surfaces, respectively.

14A and 14B are graphs showing bank amount calculation profiles when cameras are installed on the top and side surfaces, respectively.

Fig. 15 is a diagram showing upper and lower limit values for calculating the average bank amount when the camera is installed on the upper portion.

Fig. 16 is a diagram showing an example of parameter setting application.

17 is a diagram showing another example of application of parameter setting.

18 is a screen showing an example of profile storage and display.

19 is a graph showing a change in short term when a calendar is applied.

* Description of the symbols for the main parts of the drawings *

101, 102: 1st, 2nd roll

104: bank amount 105, 106: light source

107 and 108: first and second cameras 109: main controller

109a: camera control unit 109b: image processing unit

109c: bank amount measurement and database unit 109d: display unit

110: main computer 111: input and output terminal

113: automatic position control unit 114: automatic speed control unit

Claims (6)

The first roll 101 and the second roll 102 are installed on the upper side or the side of the adjacent space to brighten the bank portion 104 generated between the first roll 101 and the second roll 102. The first and second light sources 105 and 106, First and second cameras 107 and 108 for acquiring an image of the bank part 104 by the brightness emitted from the first and second light sources 105 and 106; While controlling the operations of the first and second cameras 107 and 108, the noise of the image acquired through the first and second cameras 107 and 108 is removed, the image is processed, and the amount of banks is measured to create a database. And main control unit 109 for controlling to display the corresponding bank amount to the main computer 110, and An input / output terminal unit 111 for transmitting the input / output signal of the main computer 110 to the automatic position control unit 113, the automatic speed control unit 114, and the alarm unit 115; An automatic position control unit 113 for transmitting a signal to the sub-motor 116 to automatically control the position of the conveyor C, An automatic speed control unit 114 for automatically controlling the speed of the conveyor C, And an alarm unit (115) connected to the input and output terminal units (111) for transmitting an alarm signal informing of corresponding matters when a material supply problem occurs. The method of claim 1, The main controller 109 removes noise of an image obtained through the camera controller 109a for controlling the operations of the first and second cameras 107 and 108 and the first and second cameras 107 and 108, A bank edge pattern is obtained by searching bank edges, and an image processing unit 109b for processing an image using a convolution image processing technique and an average bank amount processed through the image processing unit 109b to database the banks. Quantity measurement and database unit 109c, And a display unit 109d for obtaining the bank threshold pattern value in the image processing unit 109b and displaying the processed information in real time through data validation and data reliability checking. Control unit. The method of claim 1, And the second camera (108) and the second light source (106) are configured to measure between another calendar roll. 3. The method of claim 2, And the image processor (109b) is configured to transmit an alarm signal for bank error correction when a bank error occurs. The method of claim 4, wherein Wherein the bank error correction process the bank position to smooth the thresholded profile to eliminate the error. 3. The method of claim 2, The measurement of the bank amount is to set the measurement range limit line, the upper limit and the lower limit, and select one of the V pattern or the L pattern according to the working conditions to adjust the threshold size, threshold level, threshold calculation and DffBand values of the smoothed image. Automatic bank amount control device characterized in that for searching by dividing the bank amount.

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